Process of making electric conductors.



No. 867,658. PATENTED OCT. 8, 1907.

W. HOOPES & N. A. ROBERTSON. PROCESS OF MAKING ELECTRIC GONDUOTORS.

APPLICATION FILED IAN. 16, 1905- FIG. 3.

FIG. FIG. 2.

rum

5 R O T N E V N By tzbrneys,

WILLIAM HOOPES, OF PliTSBURG,

PROCESS OF MAKING ELECTRIC CONDUGTORS.

Application iiled l'anuary 16,1965. Serial No. 241,199

To all whom/it may czmcrm:

Be it known that we, W'ILLIAM Hoorns, residing in Iittsburg, in the county of Allegheny and State of Pennsylvania, and NORMAN A. RoBER'rsoN, residing in the borough of Brooklyn, county of Kings, city and State of New York, both citizens of the United States, have invented certain new and useful Improvements in Process for Making Electric Conductors and the Like, of which the following is a specification.

This invention providesa mode of making an improved wire rod, bar or the like, for conducting electricity. The product is called a conductor herein, though it is understood that it may be applied to other uses. 7

It is well understood that aluminium is a good conductor of electricity. It is, however, subject to flaws which impair its tensile. strength, and which, when it is strung in long spans and subjected to the weather conditions affecting aerial wires, result ultimately in transverse fractures; so that this dcliciency limits its use- Iulness for lelegraph wires and other purposes. Our invention provides a method ot' making a conductor of aluminium which is reinforced by a stronger metal; as for example by an embedded wire or core of steel or other kind of iron. By our process such a conductor can be made commercially in continuous lengths.

The process of this invention consists in the extrusion of aluminium upon a longitudinal core or wire of stronger reinforcing metal, to make a product of high conductivity andgreat strength.

The accompanying drawings illustrate a variety of cross-sections of the improved conductor, and a diaxnetral section of a machine in which the process may be carried out.

Figures 1, 2, 3, 5, 7, S and 9 are cross-sections of various forms of conductor. Fig. 4-is a central section of the machine. Fig. (Sis a perspective View of the end of another form of conductor.

In Fig. 1 the aluminium constituting the greater portion of the conductor is indicated at A, and the reinforce consists of a central wire or core of iron B.

Fig. v2 shows a conductor of the same materials but of varying proportions of aluminium and iron. The cross-section of the reinforcing core and oi the aluminium body will vary in accordance with the strengths of the different materials used, the conductivity required, and the intended use to which the conductor is to be applied as requiring long or short spans.

A valuable feature of the invention is that the alu-- minium is shrunk on the core and fits it very tightly. The reinforcingwire is naked, and the aluminium fits it so closely as to be practically integral therewith, a close examination of the cross-section showing the line between the' two materials only by reason of their differ- .ence in color. The amount of shrinkage and the conse- PENNSYLVANIA, YORK, 1v. Y.

' Specification of Letters Patent AND'NORMAN A. ROBERTSON, OFNEW PatentedOctVS, 1907.

quent intimacy of union is indicated by a comparison of Figs. 2 and 3. Fig. 3 indicates a conductor of aluminium extruded without a core, and therefore allowed to shrink to the full extent. Fig. 2 indicates wire extruded through the same die as Fig. 3, but with a By the process of extrusion the conductor can be made in continuous lengths, and can if desired be made hollow so as to increase its stiffness and to adapt it for steel core B which prevents the shrinkage of the alui minium except so far as to tightly embrace the core.

special uses, thus providing a cheap and efficient substitu'te for the conductors now in use.

In the manufacture of the aluminium conductors described, a very great pressure .isrequired. It is found that if the aluminium be somewhat liquid during the extrusion, it spurts or blows out through the die. As it cools below the point of liquidity it becomes more or come so hard as to firmly imprison the gases and prevent blow outs and yet while it is sufficiently hot to be plastic. To insure this plasticity necessitates maintaining the die and the core of the machine (where such a core is used) at or preferably just below a dull red heat. The stiffness of the aluminium'further necessitates an extraordinary pressure, and the machine for extruding the aluminium must be designed to oppose the 1nini mum of resistance to the flow of the aluminium, and to stand a very heavy pressure at a hightemperature.

A diagrammatic view of such a machine is indicated in Fig. 4, in which plungers G C work in vertical cylinders D D which connect by oblique passages E E with the mouth of the die F into which the core G of the machine projects slightly; the reinforcing wire B being carried down through the center. The die and the passages leading thereto -(and when necessary the cylinders) ders by hydraulic pressure against fixed plungers overhead, in the known manner, and the aluminium is forced down through the converging passages E at the junction of which the streams coalesce, and thence out through the die F, forming the body portion A of the conductor, and carrying with it the .t'einforcing wire B.

As soon as the aluminium passes out of the' constricted.

portion of the die it commences locool and shrink:

The amount of shrinkage is controlled by the position Correction m Letters Patent No. 867,658.

of the end of the coreG in the die.

The reinforce may be much varied in form. By distributing the some amount. of reinforcing material at a distance from the center of the conductor, it will produce a stiffer product than where it is all concentrated at the center. into a plurality of wires and extending them spirally, greater flexibility may be secured. Fig. 5 shows the reinforcing material in the form of three separate wires B arranged about half way between the center and the circumference of the cross-section. 'lhese wires B may extend stmight or spirally. If straight they will stiffen the conductor in the manner of a truss when it is supported at two opposite ends. If spiral, they make a more flexible conductor. Fig. 6 shows the reinforcing wires I 3 twisted together at the center of theconductor so as to extend spirally through it, thus giving approximately the flexibility which a wire rope would have as compared with a rod of the same material and cross-' 5 section. The desired variations in the spacing of the separate reinforcing wires may be made by suitable modifications of the core of the machine through which the reinforcing wire or wires pass. I

The shape of the conductor as a whole may be modified to suit the uses to which it is to be put, by a suitable modification in the shape of the die. For example in Figs. 7 and 8 cross-shaped forms A are illustrated, and in Fig. 9 a form A which is oblong in section. The reinforcing metal may be also cross shaped as indicated at 5 'B in Fig. 8, or may be 'of any other shape desired.

The term aluminium is used here in a general sense as applied also to alloys composed so largely of aluminium as to partake l1 rgely of its properties. For example an alloy of 90 parts aluminium, 8 parts copper, arid 2 parts zinc, may be substituted for pure aluminium. It is also within the invention to include additional elements in connection with the metals described.

record of the case in the Patent Ofiice.

[sEALl'] count of the protection from corrosion.

()r by dividing the rciuiorcing material The term iron as used here includes all forms of iron or steel. 'lhere is a special advantage in the conductor having an iron core, in that the high tensile strength of iron can be utilized while its durability is secure on ac- .lhe extrudhd aluminium covers the iron perfectly and preserves it indefinitely. 1 A

Though we have described our invention with great particularity of detail, yet it is not; to be umler'stoml that the invention is limited to the specific mnhmliment's disclosed. Various modifications thereof may be made by those skilled in the art, without departure from the invention.

What we claim is: v v

1. The process of manufacturing compound conductor of aluminium and a longitudinal reinforcing core of stronger metal, which consists in extruding the aluminium while heated to plasticity upon and enveloping the stronger metal.

2. The process of manufacturing a compound conductor of an envelop of aluminium and a-longlttudina'l reinforcing" core of stronger metal. which consists in extruding the. the aluminium at approximately a dull red heat and also cools it shrinks tightly onto the core.

3. The process of manufacturing a compound conductor of an envelop of aluminium and n longltudinul reinforcing core of stronger metal, which consists in maintaining the aluminium at a. temperature slightly below its solidifying point and extruding it upon such core. 7

4. The process of manufacturing a compound conductor of an envelop of aluminium and a longitudinal reinforcing core of stronger metal. which consists in extruding the aluminium upon such core through a die while maintaining the aluminium at approximately a dull red heat and also heating the die during the period of extrusion.

In witness whereof, we have hereunto signed our names in the presence of two subscribing witnesses.

WILLIAM HOOIES.

Witnesses THOMAS W. BAiu-niucim, ALLAN C. BAKuwi-um, J r.

In witness whereof, we have hereunto signed our names in the presence of two subscribing witnesses.

' NORMAN A. ROBERTSON.

Witnesses: v

Downsize A. ITSINA, FRED \VBITE.

It is hereby certified that in Letters Patent No. 867,658, granted October 8, 1907, upon the application of William Hoopes, of Pittsburg, Pennsylvania, and Norman A. Robertson, of New York, N. Y., for an improvement in Processes of Making Electric Conductors, an error appears in' the printed specification retquiring correction, as follows: Line 65, page 2, should be stricken out and the following words inserted instead: aluminum hot and fitting the core closely no that as it; and that the said Letters Patent should be read with this correction therein that the same may conform to the Signed and sealed this 17th day of November, A. D., 1908.

C. C. BILLINGS, Acting Commissioner of Patents.

through the die F, forming the body portion A of the conductor, and carrying with it the .t'einforcing wire B.

As soon as the aluminium passes out of the' constricted.

portion of the die it commences locool and shrink:

The amount of shrinkage is controlled by the position Correction m Letters Patent No. 867,658.

of the end of the coreG in the die.

The reinforce may be much varied in form. By distributing the some amount. of reinforcing material at a distance from the center of the conductor, it will produce a stiffer product than where it is all concentrated at the center. into a plurality of wires and extending them spirally, greater flexibility may be secured. Fig. 5 shows the reinforcing material in the form of three separate wires B arranged about half way between the center and the circumference of the cross-section. 'lhese wires B may extend stmight or spirally. If straight they will stiffen the conductor in the manner of a truss when it is supported at two opposite ends. If spiral, they make a more flexible conductor. Fig. 6 shows the reinforcing wires I 3 twisted together at the center of theconductor so as to extend spirally through it, thus giving approximately the flexibility which a wire rope would have as compared with a rod of the same material and cross-' 5 section. The desired variations in the spacing of the separate reinforcing wires may be made by suitable modifications of the core of the machine through which the reinforcing wire or wires pass. I

The shape of the conductor as a whole may be modified to suit the uses to which it is to be put, by a suitable modification in the shape of the die. For example in Figs. 7 and 8 cross-shaped forms A are illustrated, and in Fig. 9 a form A which is oblong in section. The reinforcing metal may be also cross shaped as indicated at 5 'B in Fig. 8, or may be 'of any other shape desired.

The term aluminium is used here in a general sense as applied also to alloys composed so largely of aluminium as to partake l1 rgely of its properties. For example an alloy of 90 parts aluminium, 8 parts copper, arid 2 parts zinc, may be substituted for pure aluminium. It is also within the invention to include additional elements in connection with the metals described.

record of the case in the Patent Ofiice.

[sEALl'] count of the protection from corrosion.

()r by dividing the rciuiorcing material The term iron as used here includes all forms of iron or steel. 'lhere is a special advantage in the conductor having an iron core, in that the high tensile strength of iron can be utilized while its durability is secure on ac- .lhe extrudhd aluminium covers the iron perfectly and preserves it indefinitely. 1 A

Though we have described our invention with great particularity of detail, yet it is not; to be umler'stoml that the invention is limited to the specific mnhmliment's disclosed. Various modifications thereof may be made by those skilled in the art, without departure from the invention.

What we claim is: v v

1. The process of manufacturing compound conductor of aluminium and a longitudinal reinforcing core of stronger metal, which consists in extruding the aluminium while heated to plasticity upon and enveloping the stronger metal.

2. The process of manufacturing a compound conductor of an envelop of aluminium and a-longlttudina'l reinforcing" core of stronger metal. which consists in extruding the. the aluminium at approximately a dull red heat and also cools it shrinks tightly onto the core.

3. The process of manufacturing a compound conductor of an envelop of aluminium and n longltudinul reinforcing core of stronger metal, which consists in maintaining the aluminium at a. temperature slightly below its solidifying point and extruding it upon such core. 7

4. The process of manufacturing a compound conductor of an envelop of aluminium and a longitudinal reinforcing core of stronger metal. which consists in extruding the aluminium upon such core through a die while maintaining the aluminium at approximately a dull red heat and also heating the die during the period of extrusion.

In witness whereof, we have hereunto signed our names in the presence of two subscribing witnesses.

WILLIAM HOOIES.

Witnesses THOMAS W. BAiu-niucim, ALLAN C. BAKuwi-um, J r.

In witness whereof, we have hereunto signed our names in the presence of two subscribing witnesses.

' NORMAN A. ROBERTSON.

Witnesses: v

Downsize A. ITSINA, FRED \VBITE.

It is hereby certified that in Letters Patent No. 867,658, granted October 8, 1907, upon the application of William Hoopes, of Pittsburg, Pennsylvania, and Norman A. Robertson, of New York, N. Y., for an improvement in Processes of Making Electric Conductors, an error appears in' the printed specification retquiring correction, as follows: Line 65, page 2, should be stricken out and the following words inserted instead: aluminum hot and fitting the core closely no that as it; and that the said Letters Patent should be read with this correction therein that the same may conform to the Signed and sealed this 17th day of November, A. D., 1908.

C. C. BILLINGS, Acting Commissioner of Patents.

It is hereby certified that in Letters Patent No. 867,658, granted October 8, 1907, upon the application of William Hoopes, of Pittsburg, Pennsylvania, and Norman A. Robertson, of New York, N. Y., for an improvement in Processes of Making Electric Conductors, an error appears in the printed specification requiring correction, as follows: Line 66, page 2. should be stricken out and the Following words inserted instead: aluminum hot and fitting the core closely no that as it; and that the said Letters Patent should be read with this correction therein that the seine may conform to the record of the case in the Patent Oifice. v

Signed and sealed this 17th day of November, A. D., 1908.

C. C. BILLINGS,

Acting Commissioner of Patents. 

